Pumping equipment cooling system

ABSTRACT

A system is disclosed for cooling at least one pump used to supply fluids to subterranean formations in connection with the recovery of hydrocarbons, where the cooling system includes a cooling tower connected to the at least one pump to remove heat from the at least one pump, with a plurality of fans configured in an array and oriented vertically within the cooling tower, wherein each of the plurality of fans comprises an inner flow path having an output end directed towards the cooling tower output end, and an intake end. The cooling system may further include an exhaust pipe axially located within the cooling tower to direct heated air from the exhaust pipe towards the cooling tower output end.

BACKGROUND

The present disclosure relates to methods and systems for use in subterranean operations. More particularly, the present disclosure relates to methods and systems of cooling equipment used in subterranean operations.

Pumping equipment is used in many operations associated with drilling and developing a hydrocarbon-producing wellbore within a formation. During a given operation, pumping equipment typically generates a large amount of heat, which must be removed and dissipated with a cooling system. Current cooling systems used with pumping equipment during an operation typically move air through the cooling system using large fans. These fans tend to consume a relatively high amount of energy. For example, some cooling systems can burn on the order of five-thousand gallons of fuel per year, per pump. In addition, the fan systems used in a typical cooling system can create a large amount of noise pollution.

BRIEF DESCRIPTION OF THE DRAWINGS

These drawings illustrate certain aspects of some of the embodiments of the present disclosure, and should not be used to limit or define the disclosure.

FIG. 1 is a cut-out side-view of a cooling system, incorporating certain aspects of the present disclosure.

FIG. 2, is a system diagram of a cooling system connected to the pumping system, in accordance with certain embodiments of the present disclosure.

FIG. 3A is a top-view cross-section of a cooling tower, in accordance with certain embodiments of the present disclosure.

FIG. 3B is a side-view cross-section of a cooling tower, in accordance with certain embodiments of the present disclosure.

FIG. 4 is a top-view of a plurality of air movement modules arranged in a matrix, in accordance with certain embodiments of the present disclosure.

FIG. 5 is a side-view cross-section of a cooling tower comprising an interior exhaust pipe, in accordance with certain embodiments of the present disclosure.

FIG. 6 is a top-view cross-section of a plurality of air movement modules arranged in a matrix and comprising an exhaust pipe, in accordance with certain embodiments of the present disclosure.

FIG. 7 is a cut-out side-view of a cooling tower, incorporating certain aspects of the present disclosure.

FIG. 8 is a top-view of a cooling tower comprising a plurality of shrouded fans, in accordance with certain embodiments of the present disclosure.

While embodiments of this disclosure have been depicted and described and are defined by reference to example embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and not exhaustive of the scope of the disclosure.

DETAILED DESCRIPTION

The present disclosure relates to methods and systems for use in subterranean operations. More particularly, the present disclosure relates to methods and systems of cooling equipment used in subterranean operations.

Illustrative embodiments of the present disclosure are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions may be made to achieve the specific implementation goals, which may vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.

Referring now to FIG. 1, an example cooling system 100 is shown comprising a cooling tower 110, an array of fans 112, an exhaust pipe 115, and a radiator 120. The array of fans 112 may be vertically oriented within the cooling tower 110 and move air from a suction chamber 125 toward a cooling tower output end 130. As a result, the array of fans 112 may pull air away from the radiator 120. The exhaust pipe 115 may connect to a pumping system and provide a conduit for exhaust gases generated and emitted by the pumping system. In certain embodiments, the exhaust pipe 115 may extend into the cooling tower 110 and direct exhaust gases through the cooling tower 110, as will be described below in further detail.

In certain embodiments, the array of fans 112 may pull air from the suction chamber 125, which, in turn, pulls air from the radiator 120 to cool the radiator 120. The radiator 120 may contain coolant received from a pumping system. Once circulated through the radiator 120 the coolant may be directed back to the pumping system. The cooling tower 110 may be oriented vertically such that air is directed through the cooling tower 110 and expelled upwards. As such, the lighter hot air may help increase the air flow through the cooling tower 110 without requiring additional power consumption by the array of fans 112.

Referring now to FIG. 2, a system diagram of the cooling system 100 is shown connected to elements of the pumping system. In certain embodiments, the radiator 120 a may receive pump oil 152 from the pumping system to be cooled by the cooling system 100. In certain embodiments, the radiator 120 b may receive engine coolant 154 from the cooling system. In certain embodiments, more than one radiator 120 a, 120 b may be used to circulate fluids through the cooling system 100, for example, when it is desirable to cool more than one type of fluid simultaneously. In certain embodiments, engine exhaust 156 generated by the pumping system may be routed by an exhaust pipe 415 through the suction chamber 125 and expelled through the array of fans 112.

In certain embodiments, the array of fans 112 may be comprised of a plurality of bladeless fans 200. Referring now to FIGS. 3A and 3B, a top view and a side view of an example bladeless fan 200 is shown. The bladeless fan 200 may comprise an output end 202 and an intake end 204. In certain embodiments, the bladeless fan 200 may comprise an outer wall 206. The bladeless fan 200 may comprise an outer chamber 210 and an inner flow path 215, separated by a pressure partition 220. The pressure partition 220 may be of substantially axially aligned with, and concentric with, the outer wall 206. The pressure partition 220 may be connected to the outer wall at the output end 202 and at the intake end 204.

Air within the outer chamber 210 may have an outer chamber air pressure and air within the inner flow path 215 may have an inner flow path air pressure. In certain embodiments, the bladeless fan 200 may comprise an air compressor connection 224 connected to the outer chamber 210 to allow an air compressor 226 to supply pressurized air to the outer chamber 210. In certain embodiments, the air compressor 226 connection 224 may be placed on the intake end 204 or on the output end 202.

In certain embodiments, the air compressor 226 may generate compressed air using a fuel powered motor and/or an electric powered motor. As the air compressor 226 supplies the outer chamber 210 with pressurized air, the outer chamber air pressure may be substantially higher than the inner flow path air pressure. In certain embodiments, the outer chamber air pressure may be between about 60 to about 100 psi greater than the inner flow path air pressure. In certain embodiments, the pressure difference between the outer chamber air pressure and the inner flow path air pressure may be greater than 100 psi. The outer chamber air pressure may be increased relative to the inner flow path air pressure to increased the air flow rate through the bladeless fan 200. The pressure partition 220 may comprise at least one air flow slot 225. The at least one air flow slot 225 may extend axially substantially along the entire perimeter of the pressure partition 220. In certain embodiments, the at least one air flow slot 225 may be located towards the intake end 204 of the pressure partition 220. In certain embodiments, the at least one air flow slot 225 may have a substantially consistent width of between about 0.02 inches to about 0.1 inches. The air flow slot 225 may allow air movement between the outer chamber 210 and the inner flow path 215. For example, air may flow from a relative high pressure zone in the outer chamber 210 to a relative low pressure zone in the inner flow path 215. The air flow slot 225 may be angled toward the output end 202 to direct air flowing from the outer chamber 210 toward the output end 202. In certain embodiments, the air flow slot 225 may be defined by overlapping portions 222, 223 of the pressure partition 220.

In certain embodiments, a pressure difference between the outer chamber 210 and the inner flow path 215 may result in a high velocity air flow through the air flow slot 225 and into the inner flow path 215. As pressurized air flows through the air flow slot 225 into the inner flow path 215 (shown by arrow 230), air within the inner flow path 215 may be dragged with this pressurized air toward the output end 202 (shown by arrow 232) through air-to-air frictional forces. Bernoulli forces may also cause air within the inner flow path 215 to move into the high velocity air flowing from the outer chamber 210 through the air flow slot 225. Bernoulli's principle states that increased velocity of a fluid results in decrease in pressure, as would be recognized by one of ordinary skill in the art with the benefit of the present disclosure. As a result of a relative decrease in pressure within the high velocity air flow, air within the inner flow path may be pulled into the high velocity air flow. In addition, movement of air within the inner flow path 215 toward the output end 202 may reduce the inner flow path air pressure, pulling air from the intake end 204, which may be supplied from the suction chamber.

It should be noted that, although the bladeless fan is shown by example with a hexagon shape, the bladeless fan 200 is not intended to be limited to any specific shape. For example, may form a square, pentagon, heart shape, or any other geometric shape so desired.

Referring now to FIG. 4, a top-view of an array of fans 112 comprising a plurality of bladeless fans 200 located within the cooling tower 110 is shown, according to certain embodiments of the disclosure. In certain embodiments, the outer wall 206 of each bladeless fan 200 may engage the outer wall 206 of at least one adjacent bladeless fan 200. In certain embodiments, adjacent bladeless fans 200 may share an outer wall 206. In other embodiments, adjacent bladeless fans 200 may share an outer chamber 210, as shown by example in FIG. 7.

The plurality of bladeless fans 200 may be configured in series with each other, in parallel with each other, or in a combination of both parallel and series configurations. Further addition of bladeless fans 200, in series or in parallel, may provide increased air flow rate through the cooling tower. For example, the addition of one or more bladeless fans 200 in series may increase the air flow velocity through the cooling tower 110, while the addition of one or more bladeless fans 200 in parallel may provide increased air flow area through the cooling tower 110.

In certain embodiments, each bladeless fan 200 may be connected to and associated with an individual air compressor to supply compressed air to the outer chamber through the air compressor connector. In such a configuration, the power of each bladeless fan may be controlled by adjusting the power of the compressor associated with that bladeless fan (or turning the compressor off completely). Thus, the volumetric air flow rate through the array of fans 112 may be fine tuned in response to the requirements of the cooling system. For example, while the equipment to be cooled is powering down, in an idle state, or operating at reduced capacity, the volumetric air flow rate through the array of fans 112 may be reduced by powering off selective air compressors. Likewise, if the equipment to be cooled is running at an increased capacity or generating a higher level of heat, selective air compressors may be adjusted to increase air pressure within the associated bladeless fan's outer chamber.

In certain embodiments, the air compressor 226 may be connected to the outer chamber of more than one bladeless fan. For example, if more than one bladeless fan shares an outer chamber 610, as shown by example in FIG. 7, the air compressor 226 connected to the outer chamber 610 may supply pressurized air to each bladeless fan 200 sharing the outer chamber 610. In this configuration, each bladeless fan 200 sharing an air compressor 226 may be in a bladeless fan group and be controlled in tandem with each other bladeless fan in the group.

In certain embodiments, the exhaust end of each bladeless fan 200 may be oriented vertically within the cooling tower 110, such that the intake end 204 of each bladeless fan 200 draws air from the suction chamber of the cooling tower 110. Oriented vertically, the flow of air through the bladeless fan may be further aided by rising heat (which is less dense and more buoyant than cooler air), which may reduce the energy required to move a given volume of air upward through the cooling tower 110.

Referring now to FIG. 5, in certain embodiments, the cooling system may further comprise an exhaust pipe 410 axially located in the inner flow path 215 of a bladeless fan 200. The exhaust pipe 410 may comprise an exhaust pipe wall 415 and an exhaust pipe outlet 420. The exhaust pipe wall 415 may create an exhaust flow path 435 that may provide a conduit for exhaust gases expelled by the pumping equipment. The exhaust pipe outlet 420 may direct exhaust gases toward the cooling tower output end 202. In certain embodiments, the exhaust pipe 410 may extend through substantially the center of the bladeless fan 200. In certain embodiments, the exhaust pipe 410 may comprise a muffler. During cooling, the exhaust pipe wall 415 may be heated by hot gases flowing through the exhaust pipe 410. A portion of this heat may be transferred from the exhaust pipe wall 415 to the surrounding air located within the inner flow path 215, contributing to the heat efficiency caused by the increased buoyancy of air within the inner flow path 215.

Gas may exit the exhaust pipe outlet 420 at a velocity greater than the velocity of the surrounding air within the inner flow path 215. In certain embodiments, the exhaust pipe outlet 420 may comprise a nozzle 430. In certain embodiments, the nozzle 430 may comprise a nozzle flow path with a diameter that is less than an exhaust pipe diameter. As such, the nozzle 430 may increase the velocity of gas exiting the exhaust pipe 420. High velocity air exiting the exhaust pipe outlet 420 may pull air through the cooling tower 110 by means of friction, further aiding the movement of air through the cooling tower 110 (similar to the air-to-air friction effect created by the bladeless fan as described above in reference to FIGS. 3A and 3B.

In certain embodiments, the exhaust pipe wall 415 may comprise one or more heat exchange fins 425, as shown by example in the top-down view shown in FIG. 6. The heat exchange fins 425 may be mounted on the exhaust pipe wall 415, or built into the exhaust pipe wall 415. In certain embodiments, the heat exchange fins 425 may comprise a heat conductive substance, such as copper or other substance suitable to pull heat from the exhaust pipe wall 415 as would be recognized by one of ordinary skill in the art with the benefit of this disclosure.

The heat exchange fins 425 may aid the transfer heat from the exhaust pipe wall 415 to the air in the inner flow path 215 by conducting heat from hot gases within the exhaust pipe 410 toward the air within the inner flow path 215. In certain embodiments, the heat exchange fins 425 may extend outward from the exhaust pipe wall 415, increasing the surface area in contact with air within the inner flow path 215. In certain embodiments, the heat exchange fins 425 may extend inward from the exhaust pipe wall 415, creating greater surface area for heat exchange between hot gas contained within the exhaust pipe 410 and the exhaust pipe wall 415. In addition, in certain embodiments, heat exchange fins 425 may extend inward and outward from the exhaust pipe wall 415, as shown by example in FIG. 6. The present disclosure is not intended to be limited to the number or shape of heat exchange fins 425 shown in FIG. 6. Indeed, any number and configuration of heat exchange fins 425 may be used to aid heat transfer toward air within the inner flow path 215.

In addition, as shown by example in FIG. 6, in certain embodiments, the array of fans 112 may be comprised of bladeless fans 200 having varied shapes and sizes. For example, the array of fans 112 may be configured with one or more primary bladeless fans 510, and one or more secondary bladeless fans 515. In certain embodiments, the bladeless fan array may comprise one or more tertiary fans 520.

FIG. 7 shows a cut-out side-view of the cooling tower 110 showing an embodiment comprising an array of fans 112 comprising a plurality of bladeless fans 200 and an exhaust pipe 410 extending vertically through the array of fans 112. In certain embodiments, the array of fans 112 may comprise a shared outer chamber 610 located between adjacent bladeless fans 200. As a result, a single air compressor may be connected to the shared outer chamber 610 to supply more than one bladeless fan 200 connected to the shared outer chamber 610.

FIG. 8 shows a top-view of an embodiment of the cooling tower 110, where the array of fans 112 comprises a plurality of shrouded fans 700. Each of the plurality of shrouded fans 700 comprises a plurality of blades 710 extending from a center 715. The plurality of blades 710 may be rotary type blades or non-rotary type blades. Each of the plurality of blades comprises a termination end 720 connected to a cylindrical duct 725. In certain embodiments, a motor may be connected to the center 715 to rotate the shrouded fan 700. In certain embodiments, the cylindrical duct 725 may increase the efficiency of the shrouded fan 700 as would be recognized by one of ordinary skill in the art with the benefit of the present disclosure. In addition, using a plurality of shrouded fans 700 to move air through the cooling tower 110 may reduce noise generated by the cooling system. Furthermore, the cooling system may be fine tuned and adjusted in response to changes in cooling requirements by turning on or off individual fans in the array of fans as necessary.

As described in this disclosure, the array of fans may move air through the cooling tower to cool the radiator more efficiently. The array of fans may also reduce the level of noise emitted by the cooling system. In addition, routing the exhaust pipe through the vertical cooling tower may further aid air movement through the cooling system and reduce the energy required to cool the pumping system.

Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. The indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. 

What is claimed is:
 1. A cooling system comprising: a cooling tower having a cooling tower output end, a radiator having at least one conduit which supplies a cooling fluid to at least one pump, a plurality of bladeless fans configured in an array within the cooling tower, wherein each bladeless fan comprises: an outer wall encompassing an inner flow path, wherein the inner flow path has an output end and an intake end, a pressure partition axially aligned with the outer wall, wherein the pressure partition comprises at least one air flow slot connecting the outer chamber with the inner flow path, an outer chamber located between the outer wall and the pressure partition, and an air compressor port connected to the outer chamber, and a suction chamber defined between the radiator and the plurality of bladeless fans.
 2. The system of claim 1, further comprising an exhaust pipe axially located within the inner flow path, wherein the exhaust pipe comprises an exhaust pipe wall, an exhaust pipe output end, and an exhaust flow path defined within the exhaust pipe wall.
 3. The system of claim 2, wherein the exhaust pipe further comprises at least one heat exchange fin disposed on the exhaust pipe wall.
 4. The system of claim 3, wherein the at least one heat exchange fin extends outward from the exhaust pipe wall and into the inner flow path.
 5. The system of claim 3, wherein the at least one heat exchange fin extends inward from the exhaust pipe wall and into the exhaust flow path.
 6. The system of claim 2, further comprising a nozzle engaging the exhaust pipe output end, wherein the nozzle has an inner nozzle path diameter less than an exhaust flow path diameter within the exhaust pipe to increase an exit velocity of exhaust emitted from the exhaust pipe output end.
 7. The system of claim 1, wherein the plurality of bladeless fans are in parallel with each other.
 8. The system of claim 1, wherein the outer chamber has an outer chamber air pressure and the inner flow path has an inner flow path air pressure, wherein the outer chamber air pressure is at least about 60 psi greater than the inner flow path air pressure.
 9. A system for cooling at least one pump used to supply fluids to subterranean formations in connection with the recovery of hydrocarbons, the cooling system comprising: a cooling tower connected to the at least one pump to remove heat from the at least one pump, wherein the cooling tower comprises: a cooling tower output end, a plurality of bladeless fans configured in an array and oriented vertically within the cooling tower, wherein each of the plurality of bladeless fans comprises: an inner flow path having an output end directed towards the cooling tower output end, and an intake end, a pressure partition axially located between the inner flow path and an outer chamber, wherein the pressure partition comprises at least one air flow slot connecting the outer chamber with the inner flow path, and a radiator having at least one conduit which supplies a cooling fluid to the at least one pump, a suction chamber defined between the plurality of bladeless fans and the radiator, wherein the plurality of bladeless fans are configured to pull air from the suction chamber and thereby cool the radiator by drawing heat therefrom.
 10. The system of claim 9, further comprising an exhaust pipe axially located within the inner flow path, wherein the exhaust pipe comprises an exhaust pipe wall, an exhaust pipe output end, and an exhaust flow path defined within the exhaust pipe wall.
 11. The system of claim 10, wherein the exhaust pipe further comprises at least one heat exchange fin disposed on the exhaust pipe wall.
 12. The system of claim 11, wherein the at least one heat exchange fin extends outward from the exhaust pipe wall and into the inner flow path.
 13. The system of claim 11, wherein the at least one heat exchange fin extends inward from the exhaust pipe wall and into the exhaust flow path.
 14. The system of claim 10, further comprising a nozzle engaging the exhaust pipe output end, wherein the nozzle has an inner nozzle path diameter less than an exhaust flow path diameter within the exhaust pipe to increase an exit velocity of exhaust emitted from the exhaust pipe output end.
 15. The system of claim 9, wherein the plurality of bladeless fans are in parallel with each other.
 16. The system of claim 9, wherein the outer chamber has an outer chamber air pressure and the inner flow path has an inner flow path air pressure, wherein the outer chamber air pressure is at least about 60 psi greater than the inner flow path air pressure.
 17. A system for cooling at least one pump used to supply fluids to subterranean formations in connection with the recovery of hydrocarbons, the cooling system comprising: a cooling tower connected to the at least one pump to remove heat from the at least one pump, wherein the cooling tower comprises: a cooling tower output end, a plurality of fans configured in an array and oriented vertically within the cooling tower, wherein each of the plurality of fans comprises an inner flow path having an output end directed towards the cooling tower output end, and an intake end, a radiator having at least one conduit which supplies a cooling fluid to the at least one pump, a suction chamber defined between the plurality of fans and the radiator, wherein the plurality of fans are configured to pull air from the suction chamber and thereby cool the radiator by drawing heat therefrom, and an exhaust pipe axially located within the cooling tower, wherein the exhaust pipe comprises an exhaust pipe wall, an exhaust pipe output end, and an exhaust flow path defined within the exhaust pipe wall, wherein the exhaust pipe output end directs air from the exhaust pipe towards the cooling tower output end.
 18. The system of claim 17, wherein at least one of the plurality of fans comprises a shrouded fan, wherein the shrouded fan comprises a fan with a plurality of blades connected to and extending from a fan center and a cylindrical duct connected to a termination end of each of the plurality of blades.
 19. The system of claim 17, wherein the exhaust pipe further comprises at least one heat exchange fin disposed on the exhaust pipe wall.
 20. The system of claim 17, wherein the plurality of fans are in parallel with each other. 